Compressible Paperboard Container

ABSTRACT

A container including a plurality of walls assembled into a three-dimensional body that defines an internal volume, wherein at least one of the walls includes a plurality of pre-formed fold lines that facilitate controlled deformation of the wall when the container is under compression.

FIELD

This application relates to containers and, more particularly, to paperboard containers having pre-formed fold lines configured to facilitate desired deformation of one or more walls when such paperboard containers are under compression.

BACKGROUND

Products are typically shipped to retailers in bulk by enclosing multiple product units in a container, such as a paperboard carton or box, and stacking multiple such containers on a pallet. For example, canned soup may be shipped to a retailer on a pallet supporting multiple containers, with each container containing multiple individual cans. Then, a stock clerk typically removes the individual product units from the container and presents them (e.g., on a shelf) to consumers.

Alternatives to the traditional package-ship-unpack-display model are being developed in an effort to improve operating efficiency. For example, U.S. patent application Ser. No. 12/777,444 filed on May 11, 2010, the entire contents of which are incorporated herein by reference, discloses a new system for dispensing and displaying products packaged in a container. Specifically, the system includes a dispenser having a frame, a product display area and an opening tool. The dispenser may be positioned on a retailer's shelf and loaded with product simply by placing a container comprising multiple units of product onto the frame of the dispenser. As the container is being placed onto the frame, the opening tool of the dispenser opens the container in such a manner that product rolls from the container to the product display area of the dispenser under the force of gravity.

In an effort to encourage products to move (e.g., roll) out of such containers and into the dispenser as desired, excess headspace if often provided between the products and the container. The excess headspace is believed to reduce the drag on individual product units from the container and adjacent product units. Unfortunately, when several such containers are stacked, such as on a pallet, the loads acting on the containers cause undesired deformation and creasing of the containers due to the excess headspace. Such deformation and creasing may be particularly undesirable when the external surfaces of such containers are printed with advertising indicia.

Accordingly, those skilled in the art continue with research and development efforts directed to packaging containers.

SUMMARY

In one aspect, the disclosed compressible paperboard container may include a plurality of walls assembled into a three-dimensional body that defines an internal volume, wherein at least one of the walls includes a plurality of pre-formed fold lines.

In another aspect, the disclosed compressible paperboard container may include a plurality of walls assembled into a three-dimensional body that defines an internal volume, wherein two opposed walls each include a plurality of pre-formed fold lines that facilitate controlled deformation of the wall when the container is under compression.

In another aspect, the disclosed compressible paperboard container may include six walls assembled into a three-dimensional rectilinear body that defines an internal volume, wherein a first of the six walls includes a first plurality of pre-formed fold lines, and wherein a second of the six walls includes a second plurality of pre-formed fold lines, the second wall being laterally opposed from the first wall.

In another aspect, the disclosed compressible paperboard container may include six generally rectangular walls assembled into a three-dimensional rectilinear body that defines an internal volume, wherein a first of the six walls defines a first periphery and a first plane, and includes a first plurality of pre-formed fold lines that define a first central portion and couple the first central portion with the first periphery, and wherein a second of the six walls defines a second periphery and a second plane, and includes a second plurality of pre-formed fold lines that define a second central portion and couple the second central portion with the second periphery, the second wall being laterally opposed from the first wall such that the first plane is generally parallel with the second plane, and wherein the first central portion is displaced from the first plane and the second central portion is displaced from the second plane when a compression force is applied to the body in a direction generally parallel with the first plane.

In yet another aspect, disclosed is a packaging system that includes a first container including a plurality of walls assembled into a three-dimensional body that defines an internal volume, wherein at least one of the walls of said first container includes a plurality of pre-formed fold lines, and a second container stacked on top of the first container, the second container including a plurality of walls assembled into a three-dimensional body that defines an internal volume, wherein the wall with pre-formed fold lines is creased along the pre-formed fold lines.

Other aspects of the disclosed compressible paperboard container and associated packaging system will become apparent from the following detailed description, the accompanying drawings and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front perspective view of one aspect of the disclosed compressible paperboard container;

FIG. 2 is a side elevational view, in section, of the compressible paperboard container of FIG. 1;

FIG. 3 is a side elevational view, in section, of the compressible paperboard container of FIG. 2 shown under compression and nested with an adjacent compressible paperboard container that is also under compression;

FIG. 4 is a top plan view of a container blank useful in forming the compressible paperboard container of FIG. 1;

FIG. 5 is an end perspective view of a portion of the compressible paperboard container of FIG. 1, shown in a first partially assembled configuration;

FIG. 6 is an end perspective view of the portion of the compressible paperboard container of FIG. 5, shown in a second partially assembled configuration;

FIG. 7 is a front elevational view of the portion of the compressible paperboard container of FIG. 6, shown in a fully assembled configuration; and

FIG. 8 is a front elevational view of the portion of the compressible paperboard container of FIG. 7, shown under compression.

DETAILED DESCRIPTION

Referring to FIGS. 1 and 2, one aspect of the disclosed compressible paperboard container, generally designated 8, may be formed as a three-dimensional rectilinear body 10 including a plurality of walls 12, 14, 16, 18, 20, 22 that define an internal volume 24. As shown in FIG. 2, the internal volume 24 may receive one or more products 26 therein, leaving headspace 28 between the products 26 and the container 8.

Optionally, a partition 30 may extend through the internal volume 24 of the container 8 to divide the internal volume 24 into a first chamber 32 and a second chamber 34. For example, the partition 30 may extend between laterally opposed front and rear walls 12, 16 and between laterally opposed first end and second end walls 20, 22 such that the partition 30 is generally parallel with the upper and lower walls 14, 18. Therefore, a first quantity of products 26 may be received in the first chamber 32 and may be isolated from a second quantity of products 26 received in the second chamber 34.

The container 8 shown in FIG. 1 may be formed from the container blank 100 shown in FIG. 4. In one specific implementation, the container blank 100 may be pre-cut from a sheet of paperboard substrate material to define an outer periphery 102 of the container blank 100. Those skilled in the art will appreciate that various types of paperboard-based materials may be used to form the container blank 100 and, ultimately, the container 8. As one example, the paperboard-based substrate material may be C1S paperboard, which may have a coating (e.g., clay) on a first major surface 104 thereof and an uncoated second major surface (i.e., the underside of the container blank 100 shown in FIG. 4). As another example, the paperboard-based substrate material may be C2S paperboard, which may have a coating (e.g., clay) on both the first 104 and second major surfaces thereof. Optionally, at least one side of the paperboard-based substrate material, such as the coated side, may be marked with various indicia, such as printed text and graphics.

The container blank 100 may include a plurality of pre-formed fold lines 106, 108, 110, 112, 114, 116, 118, 120, 122 that define wall panels 124, 126, 128, 130, a transition panel 132, a partition panel 134, minor end flaps 136, 138, 140, 142, major end flaps 144, 146, 148, 150 and partition flaps 152, 154. Specifically, wall panel 124 may be defined by the periphery of the blank 100 and fold lines 106, 110, 112, and may form the front wall 12 of the assembled container 8 (FIG. 1). Wall panel 126 may be defined by fold lines 106, 110, 112, 114, and may form the upper wall 14 of the assembled container 8. Wall panel 128 may be defined by fold lines 106, 110, 114, 116, and may form the rear wall 16 of the assembled container 8. Wall panel 130 may be defined by fold lines 106, 110, 116, 118, and may form the lower wall 18 of the assembled container 8. Partition panel 134 may be defined by the periphery 102 of the blank 100 and fold lines 108, 120, 122, and may form the partition 30 (FIG. 2) of the assembled container 8. Transition panel 132 may be defined by the periphery 102 of the blank 100 and fold lines 118, 120, and may function to space the partition 30 between the upper 14 and lower 18 walls of the assembled container 8. Minor 140, 142 and major 148, 150 end flaps may be defined by the periphery 102 of the blank 100 and fold line 110, and may form the first end wall 20 of the assembled container 8. Minor 136,138 and major 144,146 end flaps may be defined by the periphery 102 of the blank 100 and fold line 106, and may form the second end wall 22 of the assembled container 8. Partition flaps 152, 154 may be defined by the periphery 102 of the blank 100 and the fold lines 108, 122, respectively, and may be used to secure the partition 30 between the upper 14 and lower 18 walls of the assembled container 8.

The container 8 may be assembled by folding the container blank 100 along the longitudinal fold lines 112, 114, 116, 118, 120, 122 and connecting wall panel 124 to transition panel 132 to form the three-dimensional body 10 of the container, as shown in FIG. 5. Additionally, partition flap 154 may be connected to wall panel 128 to secure the partition 30 between the front 12 and rear 16 walls of the container 8. The connections between wall panel 124 and transition panel 132 and wall panel 128 and partition flap 154 may be made using any available technique, including using adhesives and/or mechanical fasteners.

With the container 8 partially assembled, the first 32 and second 34 chambers may be filled with product 26, as shown in FIG. 2. Then, as shown in FIGS. 5-7, the filled container 8 may be sealed by arranging the major 148, 150 and minor 140, 142 end flaps into a first layered stack 156 (FIG. 7) to form the first end wall 20 of the container 8 and arranging the major 144, 146 and minor 136, 138 end flaps into a second layered stack (not shown, but may be the same as layered stack 156) to form the second end wall 22 of the container 8.

Still referring to FIGS. 5-7, in one particular expression, the first end wall 20 may be formed by connecting major end flap 148 to major end flap 150 without connecting the major end flaps 148, 150 to the minor end flaps 140, 142. The second end wall 22 may also be formed in a similar manner.

Specifically, as shown in FIG. 5, the minor end flaps 140, 142 may be folded inward into the plane (defined by the edges of walls 12, 14, 16, 18) of the first end wall 20. Then, as shown in FIG. 6, the first major end flap 148 may be folded inward into the plane of the first end wall 20 and an adhesive 158 may be applied to the external surface 160 of the first major end flap 148. Finally, as shown in FIG. 7, the second major end flap 150 may be folded inward into generally parallel alignment with the first major end flap 148 such that the adhesive 158 connects the internal surface 162 (FIG. 6) of the second major end flap 150 to the external surface 160 of the first major end flap 148.

Thus, when a compression force F is applied to the upper wall 14 of the container 8, such as when a second container (not shown) is stacked on top of the container 8, the interconnected major end flaps 148, 150 of the end wall 20 may bow outward from the container 8, as shown in FIG. 8. As such, indicia 170 (FIG. 1) printed on the first end wall 20 is not marred by creases and the like when the container 8 is compressed.

Referring back to FIG. 1, the front wall 12 may include a plurality of pre-formed fold lines 40, 42, 44, 46, 48, 50, 52, 54, which may be formed, for example, by stamping (e.g., embossing) or scoring the front wall 12. Pre-formed fold lines 40, 42, 44, 46 may define a central portion 56 of the front wall 12, which, for example, may have a shape that corresponds to the shape of the front wall 12. For example, when the front wall 12 is generally rectangular, the central portion 56 may also be generally rectangular. Pre-formed fold lines 48, 50, 52, 54 may couple the central portion 56 to the periphery 58 of the front wall 12. For example, pre-formed fold lines 48, 50, 52, 54 may extend from the corners of the central portion 56 to the corners of the front wall 12.

Thus, when a compression force F is applied to the upper wall 14 of the container 8, as shown in FIG. 3, the front wall 12 may flex along the pre-formed fold lines 40, 42, 44, 46, 48, 50, 52, 54 such that the central portion 56 of the front wall 12 is displaced (e.g., inward) from the plane P₁ defined by the uncompressed front wall 12.

Like the front wall 12, the rear wall 16 may also include a plurality of pre-formed fold lines 40, 42, 44, 46, 48, 50, 52, 54 (FIG. 4) having a similar configuration as the pre-formed fold lines 40, 42, 44, 46, 48, 50, 52, 54 of the front wall 12, such that the central portion 56 of the rear wall 16 is displaced (e.g., outward) from the plane P₂ defined by the uncompressed rear wall 16. While not shown, one or more of the other walls 14, 18, 20, 22 of the container 8 may also include pre-formed fold lines to facilitate controlled deformation.

Still referring to FIG. 3, when two adjacent containers 8, 8′ are placed under compression (i.e., a compression force F is applied to the upper walls 14 of the containers 8, 8′), the outwardly extending rear wall 16 of the first container 8 may nest with the inwardly extending front wall 12′ of the second container 8′. Therefore, the disclosed compressible paperboard containers 8 may be stacked several containers high and in close proximity to adjacent stacks of containers 8, without compromising the controlled deformation achieved by the pre-formed fold lines 40, 42, 44, 46, 48, 50, 52, 54 on the front 12 and rear 16 walls of the containers 8.

While the disclosed compressible paperboard container 8 is described with reference to a rectangular carton having six walls 12, 14, 16, 18, 20, 22, those skilled in the art will appreciate that various shapes and configurations may be used without departing from the scope of the present disclosure.

Accordingly, the disclosed compressible paperboard container 8 is configured to deform in a controlled manner when a compression force, such as another container, is applied thereto, thereby reducing or eliminating the undesirable random creasing and deformation that occurs when prior art containers are placed under compression. Furthermore, the deformation of the disclosed compressible paperboard container 8 may be controlled such that adjacent containers 8 nest under compression.

Although various aspects of the disclosed compressible paperboard container have been shown and described, modifications may occur to those skilled in the art upon reading the specification. The present application includes such modifications and is limited only by the scope of the claims. 

1. A container comprising a plurality of walls assembled into a three-dimensional body that defines an internal volume, wherein at least one wall of said plurality of walls comprises a plurality of pre-formed fold lines.
 2. The container of claim 1 wherein said plurality of walls comprise paperboard.
 3. The container of claim 2 wherein said paperboard is C1S paperboard.
 4. The container of claim 1 wherein at least one wall of said plurality of wall is marked with indicia.
 5. The container of claim 1 wherein said plurality of pre-formed fold lines are configured to facilitate controlled deformation of said wall when said body is under compression.
 6. The container of claim 1 wherein said wall includes a periphery, and wherein said plurality of pre-formed fold lines define a central portion of said wall and couple said central portion with said periphery.
 7. The container of claim 6 wherein said wall is generally rectangular and includes four corners, and wherein said central portion is generally rectangular and includes four corners.
 8. The container of claim 7 wherein a first pre-formed fold line of said plurality extends from a first corner of said four corners of said wall to a first corner of said four corners of said central portion, a second pre-formed fold line of said plurality extends from a second corner of said four corners of said wall to a second corner of said four corners of said central portion, a third pre-formed fold line of said plurality extends from a third corner of said four corners of said wall to a third corner of said four corners of said central portion, and a fourth pre-formed fold line of said plurality extends from a fourth corner of said four corners of said wall to a fourth corner of said four corners of said central portion.
 9. The container of claim 6 wherein said wall defines a plane, and wherein said central portion is displaced from said plane when a compression force is applied to said body in a direction generally parallel with said plane.
 10. The container of claim 9 wherein said central portion is displaced into said internal volume.
 11. The container of claim 9 wherein said central portion is displaced away from said internal volume.
 12. The container of claim 1 wherein two opposed walls of said plurality of walls each comprise said plurality of pre-formed fold lines.
 13. The container of claim 1 wherein two opposed walls of said plurality each include a major flap extending therefrom, and wherein one wall of said plurality comprises said major flap of said first opposed wall connected to said major flap of said second opposed wall, with the proviso that said major flaps are not connected to any other flaps.
 14. A container comprising six generally rectangular walls assembled into a three-dimensional rectilinear body that defines an internal volume, wherein a first wall of said six walls comprises a first plurality of pre-formed fold lines, and wherein a second wall of said six walls comprises a second plurality of pre-formed fold lines, said second wall being laterally opposed from said first wall.
 15. The container of claim 14 wherein said six walls comprise paperboard.
 16. The container of claim 14 wherein said first and second pluralities of pre-formed fold lines are configured to facilitate controlled deformation of said first and second walls when said body is under compression.
 17. The container of claim 14 wherein said first and second walls each include a periphery, and wherein said first plurality of pre-formed fold lines define a central portion of said first wall and couple said central portion of said first wall with said periphery of said first wall, and wherein said second plurality of pre-formed fold lines define a central portion of said second wall and couple said central portion of said second wall with said periphery of said second wall.
 18. The container of claim 17 wherein said first wall defines a first plane and said second wall defines a second plane, and wherein said central portion of said first wall is displaced from said first plane into said body and said central portion of said second wall is displaced from said second plane away from said body when a compression force is applied to said body.
 19. The container of claim 14 wherein said first wall includes a first flap extending therefrom and second wall includes a second flap extending therefrom, and wherein laterally opposed third and fourth walls of said six walls each include a major flap extending therefrom, and wherein a fifth wall of said six walls comprises said major flap extending from said third wall connected to said major flap extending from said fourth wall, with the proviso that said major flaps are not connected to said first and second flaps.
 20. A packaging system comprising: a first container comprising a plurality of walls assembled into a three-dimensional body that defines an internal volume, wherein at least one wall of said plurality of walls of said first container comprises a plurality of pre-formed fold lines; and a second container stacked on top of said first container, said second container comprising a plurality of walls assembled into a three-dimensional body that defines an internal volume, wherein said wall is creased along said plurality of pre-formed fold lines. 